MAYO 12000 Series Operator's Manual And Parts Book

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MAYO

WASHER POLISHER

MODEL 12000 SERIES

OPERATOR'S MANUAL

AND PARTS BOOK

Table of Contents

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Summary of Contents for MAYO 12000 Series

Page 1 MAYO WASHER POLISHER MODEL 12000 SERIES OPERATOR'S MANUAL AND PARTS BOOK...
Page 2 This warranty does not apply to any machine that has been altered outside the factory in any way so as, in the judgement of Mayo, to affect its operation, reliability or safety, or which has been subject to misuse, neglect or accident.
Page 3 MAYO WASHER POLISHER 12000 SERIES WARRANTY REGISTRATION FORM & INSPECTION REPORT WARRANTY REGISTRATION (please print) This form must be filled out by the dealer and signed by both the dealer and the customer at the time of deliv- ery. Customer’s Name Dealer Name Address Address City, State/Province, Code City, State/Province, Code Phone Number ( Phone Number ( Contact Name Model Serial Number...
Page 4 SERIAL NUMBER LOCATION Always give your dealer the serial number of your Mayo Potato Washer Polisher when ordering parts or requesting service or other information. The serial number plate is located where indicated. Please mark the number in the space provided for easy reference.
Page 5: Table Of Contents
TABLE OF CONTENTS SECTION DESCRIPTION PAGE Introduction ................1 Safety ..................2 General Safety ...............3 Equipment Safety Guidelines .........4 Safety Training ...............5 Safety Signs ..............5 Preparation ..............6 Installation Safety ............7 Operating Safety ............7 Maintenance Safety ............8 Lock-Out Tag Out Safety ..........8 2.10 Storage Safety ...............8 2.11 Transport Safety.............8...
Page 6: Introduction
INTRODUCTION Congratulations on your choice of a Mayo Model 12000 SERIES Potato Washer Polisher and welcome to Mayo's quality line of potato handling equipment. This equipment is designed and manufactured to meet the needs of a discriminating buyer in the agricultural industry for the loading and processing of harvest yields.
Page 7: Safety
If you have any questions not answered in this manual or require additional copies or the manual is damaged, please contact your dealer or Mayo, P.O. Box 497, Bus Highway 2, East Grand Forks, Minnesota, 56721. (Telephone) 218-773-1234, (FAX) 218-773-6693 or toll free at 1-800-223-5873.
Page 8: General Safety
1. Read and understand the Op- YOU are responsible for the SAFE operation and erator's Manual and all & safety maintenance of your Mayo Potato Washer Polisher. signs before supplying power, YOU must ensure that you and anyone else who is...
Page 9: Equipment Safety Guidelines
EQUIPMENT SAFETY GUIDELINES 1. Safety of the operator and bystanders is one of 6. This equipment is dangerous to children and the main concerns in designing and developing persons unfamiliar with its operation. The opera- a machine. However, every year many accidents tor should be a responsible, properly trained and occur which could have been avoided by a few physically able person familiar with farm machin-...
Page 10: Safety Training
SAFETY TRAINING SAFETY SIGNS 1. Keep safety signs clean and legible at all 1. Safety is a primary concern in the design and manufacture of our products. Unfortunately, our times. efforts to provide safe equipment can be wiped out by a single careless act of an operator or 2.
Page 11: Preparation
PREPARATION 1. Never operate the Washer Polisher and auxiliary 5. Operate only in daylight or good artificial light. equipment until you have read and completely understand this manual, the auxiliary equipment 6. Be sure machine is properly anchored, adjusted Operator's Manual, and each of the Safety Mes- and in good operating condition.
Page 12: Installation Safety
2. Turn machine OFF, shut down and lock out power supply (safety lockout devices are avail- able through your Mayo dealer parts depart- 2. Position the machine on firm, level ground before ment), engage drum anchor lock pin and wait operating.
Page 13: Maintenance Safety
3. Turn machine OFF, shut down and lock out power supply (safety lockout devices are 2. If required, make sure the unit is solidly blocked available through your Mayo dealer parts de- partment), engage drum anchor lock pin and wait for all moving parts to stop before servic- 3.
Page 14: Electrical Safety
(safety lockout devices are cements. The hydraulic system operates under available through your Mayo dealer parts de- extremely high-pressure. Such repairs will fail partment), engage drum anchor lock pin and...
Page 15: Employee Sign-Off Form
Mayo Manufacturing, Inc. follows the general Safety Standards specified by the American Society of Agricul- tural Engineers (ASAE) and the Occupational Safety and Health Administration (OSHA). Anyone who will be operating and/or maintaining a Mayo built machine must read and clearly understand ALL Safety, Operating and Maintenance information presented in this manual.
Page 16: Safety Sign Locations
SAFETY SIGN LOCATIONS The types of safety signs and locations on the equipment are shown in the illustrations that follow. Good safety requires that you familiarize yourself with the various Safety Signs, the type of warning and the area, or particular function related to that area, that requires your SAFETY AWARENESS.
Page 17 The types of safety signs and locations on the equipment are shown in the illustrations that follow. Good safety requires that you familiarize yourself with the various Safety Signs, the type of warning and the area, or particular function related to that area, that requires your SAFETY AWARENESS. •...
Page 18 The types of safety signs and locations on the equipment are shown in the illustrations that follow. Good safety requires that you familiarize yourself with the various Safety Signs, the type of warning and the area, or particular function related to that area, that requires your SAFETY AWARENESS. •...
Page 19: Operation
TO THE NEW OPERATOR OR OWNER Many features incorporated into this machine are the The Mayo Manufacturing Potato Washer Polisher is designed to wash potatoes to remove dirt, mud and result of suggestions made by customers like you. residue prior to shipment for processing. Be familiar...
Page 20: Machine Components
MACHINE COMPONENTS The Mayo Manufacturing Potato Washer Polisher consists of an intake, wash bed and discharge gate for cleaning potatoes prior to shipment for processing. Generally a washer is a component within a conveying line and is used to clean the potatoes.
Page 21: General Operation Theory
GENERAL OPERATION THEORY A Potato Washer Polisher is positioned in the line of conveying equipment that loads trucks to take the potatoes for processing. This unit can be located at a storage or transfer facility and used prior to the potatoes being loaded into the transport truck.
Page 22: Machine Break-In
A. Read Washer Polisher and auxiliary equipment longevity of your new Mayo Washer Polisher. The manuals before starting. checklist should be performed before operating the Washer and prior to each operation thereafter.
Page 23: Controls
CONTROLS It is recommended that all operators review this section of the manual to familiarize themselves with the location and function of all machine con- trols before starting. Some machines may vary slightly due to custom features but they are similar and all controls are labelled.
Page 24 Normally the water from the bottom sump is filtered or cleaned and then recycled back through the wash nozzle sys- tem. The Mayo 12000 Series Recirculating Tank works well for recycling and cleaning anadequate supply of water.
Page 25: Operating
OPERATING OPERATING SAFETY • Install and secure all guards before operat- • Read Operator's Manual before starting. ing. • Review safety instructions annually. • Keep hands, feet, hair and clothing away from • Turn machine OFF, shut down and lock out moving parts.
Page 26 5. Starting Machine: a. Clear the area of bystanders. Know where everyone is before starting. b. Place all controls in the OFF position. c. Turn the power to the machine ON at the master panel. d. Turn the master power switch ON (refer to section 4.6 Controls).
Page 27 8. Equipment Attachment: Provide a means for bringing a flow of po- tatoes into the intake end and a means of removing them from the discharge. Since the machine is positioned on the ground for operation, it will not move. Do not allow the auxiliary equipment to move.
Page 28 11. Wash Water: Water is used with the brushes to clean the potatoes as they move through the cleaning bed. Water is distributed throughout the ma- chine with a pipe in the center of the drum. Holes in the bottom of the pipe distribute the water over the entire cleaning bed.
Page 29 13. Brush Rollers: The machine is designed with a series of brush rollers arranged in a tube or drum for the potatoes to move through for cleaning. The drum itself rotates and each individual brush roller rotates. The dual action of the rotating drum and rollers insures that all sides of the potato get brushed and cleaned as it moves through the drum.
Page 30 15. Water Quality: It is recommended that the customer provide a means to clean the wash water as it is pumped out of the sump. Although filters or cleaning systems remove the dirt and trash, they do not remove all the fines. After recy- cling the water for a period of time, the fines will accumulate and the water will get dirty.
Page 31: Storage
.9 STORAGE 8. Inspect all the water hoses, lines, fittings and holes. STORAGE SAFETY Tighten any loose fittings. Replace any hose that is badly cut, nicked, abraded or separating from a fitting. Replace any damaged components. • Store the Washer Polisher on a firm level sur- face.
Page 32: Service And Maintenance
(safety lockout devices are available failure. through your Mayo dealer parts department), and wait for all moving parts to stop before 2. Wipe grease fitting with a clean cloth before greas- servicing, adjusting, maintaining or repairing.
Page 33 ..3 SERVICING INTERVALS Hours or Daily The period recommended is based on normal op- erating conditions. Severe or unusual conditions may require more frequent servicing. 1. Check the condition of the brush rollers. Re- move any entangled material. Clean if dirty. Replace if damaged.
Page 34 Weekly or 0 Hours 1. Grease brush roller shaft bearings on the intake end with 1 shot of grease. IMPORTANT Only sealed bearings are used on the conveyor bearings. Sealed bearings should never be greased more often than weekly or every 50 hours.
Page 35 Weekly or 0 Hours 4. Check the drive belt tension and pulley align- ment. a. Drum rotation drive. Belt Adjuster Fig. 0 DRUM ROTATION DRIVE...
Page 36 b. Brush roller rotation drive. Belt Adjuster Idler Pulley Fig. BRUSH ROLLER ROTATION DRIVE...
Page 37 00 Hours or Annually 1. Check the oil level in each speed reducing gear box (1 location each gear box). WARNING Machine is shown with guards re- Drum Drive moved for illustrative purposes only. Do not operate with guards opened. Roller Drive Fig.
Page 38 .. SERVICE RECORD See Lubrication and Maintenance sections for details of service. Copy this page to continue record. ACTION CODE: CHECK CHANGE CLEAN GREASE RE-PACK HOURS SERVICED MAINTENANCE HOURS OR DAILY CK Brush Rollers CK Water Distribution Holes 0 HOURS OR WEEKLY CK Belt Drive Tension CK Belt Drive Pulley Alignment Brush Roller Intake End Bearings...
Page 39: Maintenance
. MAINTENANCE By following a careful service and maintenance pro- gram on your machine, you will enjoy many years of trouble-free use. .. ELECTRIC SYSTEM INSPECTION Electricity provides power to all systems on the Washer Polisher. To maintain the integrity of each system and provide a safe working environment for the operator, it is important that a daily inspection be done to make sure that all systems and components...
Page 40 .. SPEED REDUCER GEARBOX OIL Each drum and brush roller rotation system is driven by an electric motor that is attached to a high ratio speed reducing gearbox to give the required operating speed. Each gearbox is equipped with a drain, level and fill plug. Every 200 hours, the oil level should be checked.
Page 41 ..3 BREATHER CLEANING Each gearbox is equipped with a breather in the fill plug that vents the internal pressure to atmos- phere. As the gearbox temperature increases and decreases during the operating and stopped modes, the pressure in the gearbox will increase or decrease if it is not vented to atmosphere.
Page 42 .. DRUM ROTATION DRIVE SYSTEM Power to rotate the drum is provided by a speed reducer gearbox and electric motor positioned on the top of the frame. The belt tension shouls be snug and tight enough to prevent slipping during operation. Adjust the gearbox mounting base to set the tension and alignment of the sys- tem.
Page 43 .. BRUSH ROLLER BELT DRIVE Power to rotate the brush rollers is provided by a speed reducing gearbox and electric motor positioned on the top of the frame. The belt ten- WARNING sion should be snug and tight enough to prevent slipping during operation.
Page 44 5. Pulley Alignment: a. Sight across the face of pulleys to check the alignment. b. If the pulley faces are more than 1/16 inch (1.5 mm) from the straight edge, the pulleys must be aligned. c. Loosen hub bolts on drive pulley or move the gearbox.
Page 45: Troubleshooting
TROUBLESHOOTING The Mayo Washer Polisher uses a flow of water to scrub potatoes as they move through the machine. It is a simple and reliable system that requires minimum maintenance. In the following section, we have listed many of the problems, causes and solutions to the problems that you may encounter.
Page 46: Parts List
PARTS LIST The manual contains a parts list for your machine. It is divided into major sections which correspond to the groups shown in the Table of Contents and the accompanying illustration. Each page lists the contents of that page, each of which consists of exploded views and related listings. WHEN ORDERING PARTS Always give your dealer the model and Serial Number of your machine to assist him in ordering...
Page 54: Specifications
SPECIFICATIONS MECHANICAL SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE...
Page 55: Bolt Torque
BOLT TORQUE CHECKING BOLT TORQUE The tables shown below give correct torque values for various bolts and capscrews. Tighten all bolts to the torques specified in chart unless otherwise noted. Check tightness of bolts periodically, using bolt torque chart as a guide. Replace hardware with the same strength bolt. ENGLISH TORQUE SPECIFICATIONS Bolt Torque* Bolt...
Page 56: Hydraulic Fitting Torque
HYDRAULIC FITTING TORQUE TIGHTENING O-RING FITTINGS * 1. Inspect O-ring and seat for dirt or obvious Recommended defects. Turn To Tighten Thread Across (After Finger 2. On angle fittings, back the lock nut off until Size Flats Torque Value* Tightening) washer bottoms out at top of groove.
Page 57: Electrical Schematic
ELECTRICAL SCHEMATIC Line phasing, line voltage, control voltage, and accessory options can vary sub- stantially for each machine. Please contact factory at 1-800-223-5873 for your machine's specific electrical lay- out.
Page 58: Index
INDEX PAGE PAGE Introduction ............1 Safety ..............2 Index ..............53 Electrical Safety ..........9 Employee Sign-Off Form ......10 Equipment Safety Guidelines .....4 General Safety..........3 Hydraulic Safety .........9 Operation ............14 Installation Safety ........7 Controls ............18 Lock-Out Tag-Out Safety ......8 General Operation Theory ......16 Maintenance Safety ........8 Machine Break-In ........17 Operating Safety.........7...
Page 59 MAYO MANUFACTURING CO. BUS HIGHWAY 2 BOX 497 EAST GRAND FORKS, MN 56721 PHONE (218) 773-1234 TOLL FREE (800) 223-5873 FAX (218) 773-6693 PRINTED IN USA ISSUE DATE: MARCH 2010 PART NUMBER: XXX-XXX...